DWS 1160 1

PVC Pipes

DEPARTMENT OF WATER AFFAIRS & FORESTRY

SPECIFICATION DWS 1160

DESIGN, MANUFACTURE, SUPPLY AND

INSTALLATION OF

POLYVINYL CHLORIDE (PVC)

PRESSURE PIPES AND FITTINGS

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PVC Pipes

REVISED : MAY 1997

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PVC Pipes

RMH/10013639.dc

CLAUSE CONTENTS PAGE NUMBER

SECTION 1 : GENERAL

1.1 Scope........................................................................................................................... 4
1.2 References................................................................................................................... 4
1.3 Health and Safety......................................................................................................... 5
1.4 Inspection..................................................................................................................... 6

SECTION 2 : MATERIALS

2.1 General........................................................................................................................ 6
2.2 Softening Point............................................................................................................. 6
2.3 Colour........................................................................................................................... 6
2.4 Quality Control............................................................................................................. 7
2.5 Rubber Sealing Rings.................................................................................................. 7
2.6 Flange Gaskets............................................................................................................ 7
2.7 Fittings and Valves....................................................................................................... 7

SECTION 3 : MANUFACTURE OF PIPES AND COUPLINGS

3.1 Pipes : PART I.............................................................................................................. 9

3.2 Pipes : PART II........................................................................................................... 11

SECTION 4 : DESIGN CONSIDERATIONS

4.1 Classification : PART I................................................................................................12

4.2 Classification : PART II...............................................................................................14
4.3 Pipe Design................................................................................................................ 15
4.4 Pipeline Design.......................................................................................................... 16
4.5 Corrosion Protection................................................................................................... 19

SECTION 5 : CONSTRUCTION

5.1 Transport, packaging, handling and storage..............................................................20

5.2 Trenching, laying and backfilling................................................................................21
5.3 Cleaning, testing and sterilization..............................................................................24
5.4 Measurement and payment........................................................................................ 27

THE TOTAL NUMBER OF PAGES IN THIS SPECIFICATION IS 27 PAGES

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PVC Pipes

SECTION 1 : GENERAL

1.1 SCOPE

This specification covers the design, manufacture, construction and installation

of uPVC (unplasticised polyvinyl chloride) and MPVC (modified unplasticised
polyvinyl chloride) pressure pipes, fittings and joints suitable for conveying
natural or potable water. Clauses referring specifically to uPVC are classified as
PART I and Clauses referring specifically to MPVC are classified as PART II. All
other Clauses refer to both types.
Notes:
(a) All manufacturers of uPVC and MPVC pipes, fittings and couplings must be
quality listed by the South African Bureau of Standards to comply with SABS
ISO 9002.
(b) It is very important that all pipes be covered with some soil immediately after
laying so as to limit any unnecessary movement of the pipe after the initial
contraction due to the change in temperature.
(c) Since bitumen deteriorates in strong sunlight, bitumen-dipped fittings shall
not be stored in the open for longer than one month where external
protection is a necessity.
(d) This specification cannot and must not be used as a text book, nor can it
relieve the designer and the contractor of the need for making a thorough
study of the theoretical and practical problems that may occur in the field.

(e) The use of PVC in this Specification, refers to both uPVC and MPVC.

( f) For guidance on design and construction, refer to the following specifications

as applicable:

 Departmental specification, DWS 1110: Clauses, 3.16, 4 and 7.

 SABS 1200: Section DB (pipe trenches) and LB (bedding).
 Pipe manufacturer's instructions.

1.2 REFERENCES

The following standard specifications, codes of practice and regulations are referred
to and shall apply as specified hereinafter. The latest issue shall apply:

DWS 1110 : Construction of pipelines

DWS 2510 : Supply of valves
SABS 471 : Portland cement (ordinary, rapid-hardening and
sulphate-resisting)
SABS 626 : Portland blastfurnace cement
SABS 664 : Cast iron gate valves for water works
SABS 831 : Portland cement 15 and rapid-hardening Portland
cement 15

SABS 974 : Rubber joint rings for water, sewer and drainage
systems, Part 1
SABS 936 : Spheroidal Graphite Iron Castings
SABS 966 : Components of Unplasticised Polyvinyl Chloride
(uPVC) Pressure Pipe Systems for potable water.
SABS 1200 : Standard specification for civil engineering
construction:
Section DB : Pipe Trenches
Section L : Medium-pressure pipelines, Clause
7,3 standard hydraulic pipe test
Section LB : Bedding
SABS 1283 : Unplasticised polyvinyl chloride (uPVC) pressure pipes
and couplings for cold water services in underground
mining.
SABS 0102 : The selection of pipes for buried pipelines
Part I : General
Part III : Semi-flexible pipes
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PVC Pipes

SABS 0112 : The installation of polyethylene and unplasticized polyvinyl

chloride pipes
BS 1832 : Compressed asbestos fibre jointing.
BS 3505 : Unplasticised polyvinyl chloride pressure pipes for cold
potable water.
BS 4504 : Circular flanges for pipes, valves and fittings.
Section 3.1 : Specification for steel flanges
Section 3.2 : Specification for cast iron flanges
BS 4865 : Dimensions of gaskets for flanges to BS 4504.
Part 1 : Specification for non-metallic flat
gaskets.
BS 6920 : Suitability of non-metallic products for use in contact with
water intended for human consumption with regard to their
effect on the quality of the water
DIN 8061 : A1:1991 Unplasticised polyvinyl chloride pipes :
General quality requirements and testing
ISO 1167 : Plastic pipes for the transport of fluids: determination of
the resistance to internal pressure.
ISO 1628 : Plastics determination of viscosity number and limiting
viscosity number. Part 2: PVC resins.
ISO 4422 : Pipes and fittings made of unplasticised polyvinyl chloride
for water supply specifications
ISO 9002 : Quality systems : Model for quality assurance in
production and installation.
JASWIC : R55 1993 : Requirements for MPVC pressure
pipes.

1.3 HEALTH AND SAFETY

Safety precautions to avoid risk to health and safety of the public and all employees,
and to prevent damages to the works and private property, must be observed at all
times.
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PVC Pipes

1.4 INSPECTION
The integrity of a properly designed pipeline depends mainly on the standards and
quality of inspection applied at each stage of manufacture and construction.
Special attention shall be paid to:

(a) Inspection before installation for possible damage to the ends of each pipe.

(b) Correct bedding to ensure that leakage is not caused by undue settlement.

(c) Proper jointing, anchoring, testing and backfilling.

Factory inspection of the plant, manufacturing process, supervision and adjudication

of test records shall be carried out by an independent inspectorate appointed by the
Employer to act on behalf of the Engineer. The manufacturer shall make available
for the inspector's use without additional charge, all necessary facilities required for
inspection.

SECTION 2 : MATERIALS

2.1 GENERAL

uPVC pipes and post formed bends shall be made of unplasticised polyvinyl chloride
manuractured in accordance with SABS 966. For MPVC, the material shall be an
alloy or compound of unplasticised polyvinyl chloride. The alloy or compound shall
consist substantially of unplasticised polyvinyl chloride resin to which shall be added
only those materials necessary to facilitate the production of sound durable pipes and
bends to this specification. The unplasticised polyvinyl chloride resin shall have a
"K"-value of not less than 66 when tested in accordance with ISO 174. All additives
shall be uniformly dispersed. None of these additives shall be used, separately or
together, in quantities sufficient to constitute a toxic, organoleptic or microbial growth
hazard, impair the fabrication or welding properties of the product or impair
conformance with the chemical and physical properties specified in this specification.
The use of the manufacturer's own reprocessable material produced during the
manufacturing and testing of products conforming to this specification is permissible.
No reprocessable nor recyclable material obtained from external sources shall be
used.

2.2 SOFTENING POINT

2.2.1 PART I : uPVC

The Vicat softening point of the pipe material, when measured in accordance with
SABS 966 shall not be lower than 76C in the case of pipes and not lower than 72C
in the case of fittings.

2.2.2 PART II : MPVC

The Vicat softening point of the pipe material, when measured in accordance with
SABS 966 shall not be lower than 80C.

2.3 COLOUR

2.3.1 PART I : uPVC

The colour of the pipe shall be light blue in line with SABS 966 paragraph 3.1.6.

2.3.2 PART II : MPVC

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PVC Pipes

The colour of the pipe shall be dark blue.

2.4 QUALITY CONTROL

The manufacturer must have a quality control system in accordance with ISO 9002.

2.5 RUBBER SEALING RINGS

The rubber sealing rings shall comply with the requirements of SABS 974 Part I.

2.6 FLANGE GASKETS

Gaskets for flanged joints shall be in one piece, full face for Type A (flat face) flange
facings for use with flanges complying with BS 4504. The dimensions of gaskets
shall comply with BS 4865. The gasket shall be of compressed fibre (chrysotile
asbestos) with a suitable binder, 3 mm thick to comply with BS 1832. For pressures
up to and including 1,6 MPa, fabric inserted rubber, 3mm thick may be used.
Note:
(a) Where gaskets come into contact with potable water then materials shall
comply with BS 6920, Part I.
(b) Gaskets shall be protected from unnecessary exposure of ultraviolet
radiation, light and ozone.

2.7 FITTINGS AND VALVES

2.7.1 For sizes up to 250 mm diameter

Fittings such as pressure bends, adaptors and double sockets for sizes up to 250 mm
shall be manufactured from either uPVC or MPVC pipes, as applicable, to suit the
relevant pipe classes. All other fittings in this size range shall be manufactured from
Spheroidal Graphite Iron (SG Iron) and shall be bitumen dipped. All the above-
mentioned fittings shall use the same rubber ring joint as used in the straight uPVC
or MPVC pipe.

2.7.2 For sizes larger than 250 mm

For sizes larger than 250 mm all fittings must be fabricated in steel and must be
provided with plain ends. All steel fittings must be painted on both the inside and the
outside with an epoxy based paint to a dry film thickness of 300 micrometres.
Flexible couplings shall be used to connect steel fittings and plain ended pipes.

2.7.3 Valves

Valves shall be selected to be suitable for the duty required and shall comply with the
Department's Specification DWS 2510. SG Iron Gate valves shall be manufactured
in accordance with SABS 664 with socket ends for uPVC or MPVC piping, as
applicable, up to 200 mm diameter. For larger pipes flanged valves shall be used
with the appropriate flanged adapters. Valves shall be mounted vertically with feet
grouted in a concrete base.

SECTION 3 : MANUFACTURE OF PIPES AND COUPLINGS

3.1 PIPES : PART I : uPVC

uPVC pressure pipes shall be manufactured in accordance with the requirements of

SABS 966. The factory shall be accredited in accordance with ISO 9002. The
standard effective length shall be 6 metres which shall exclude the integral rubber
ring joint.
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PVC Pipes

Outside diameters listed, are constant for all classes of a given size and shall be
measured on the barrel of the pipe. There shall be seven classes as shown in Table
3.1.1 (the required class will be specified by the Engineer):

Table 3.1.1 : Classes of uPVC Pipe

Class Maximum working pressure at 25 C

kPa Head of water (m)

4 400 40
6 600 60
9 900 90
12 1200 120
16 1600 160
20 2000 200
25 2500 250

Nominal sizes shall be as shown in Table 3.1.2 (the required size will be specified by
the Engineer).
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PVC Pipes

Table 3.1.2: Nominal sizes and wall thickness for uPVC pipes
Wall Thickness (mm)
Nominal Outside
Size Diameter (mm)
(mm) Class 4 Class 6 Class 9 Class 12 Class 16 Class 20 Class 25
Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max

16 16.0 16.3 1.5 1.9

20 20.0 20.3 1.5 1.9 1.9 2.3

25 25.0 25.3 1.5 1.9 1.9 2.3 2.3 2.8

32 32.0 32.3 1.5 1.9 1.8 2.2 2.4 2.9 2.9 3.4

40 40.0 40.3 1.5 1.9 1.8 2.2 2.3 2.8 3.0 3.5 3.7 4.3

50 50.0 50.3 1.8 2.2 2.2 2.7 2.8 3.3 3.7 4.3 4.6 5.3

63 63.0 63.3 1.9 2.3 2.7 3.2 3.6 4.2 4.7 5.5 5.8 6.7

75 75.0 75.3 1.5 1.9 2.2 2.7 3.2 3.8 4.8 5.0 5.6 6.5 6.9 8.0

90 90.0 90.3 1.8 2.2 2.7 3.1 3.9 4.5 5.1 5.9 6.7 7.8 8.2 9.5

110 110.0 110.4 1.8 2.2 2.6 3.1 3.9 4.5 5.1 5.9 6.7 7.8 8.2 9.5 10.0 11.5

125 125.0 125.4 2.0 2.4 3.0 3.5 4.4 5.1 5.8 6.7 7.6 8.8 9.3 10.8 11.4 13.1

140 140.0 140.5 2.3 2.6 3.3 3.9 4.9 5.7 6.5 7.5 8.5 9.8 10.4 12.0 12.7 14.6

160 160.0 160.5 2.6 3.1 3.8 4.4 5.6 6.5 7.4 8.6 9.7 11.2 11.9 13.7 14.6 16.8

180 180.0 180.6 2.9 3.4 4.2 4.9 6.3 7.3 8.3 9.6 10.9 12.6 13.4 15.5 16.4 18.9

200 200.0 200.6 3.1 3.7 4.7 5.3 7.0 8.1 9.2 10.6 12.1 14.0 14.9 17.2 18.2 20.9

225 225.0 225.7 3.5 4.1 5.2 6.0 7.9 9.1 10.3 11.9 13.6 16.7 16.7 19.3 20.5 23.6

250 250.0 250.8 3.9 4.5 5.9 6.8 8.7 10.1 11.5 13.3 15.1 17.4 18.6 21.4 22.7 26.1

280 280.0 280.9 4.4 5.1 6.6 7.6 9.8 11.5 12.9 14.9 16.9 19.5

315 315.0 316.0 5.0 5.8 7.4 8.6 11.0 12.7 14.5 16.7 19.0 21.9

355 355.0 356.0 5.3 6.5 8.4 9.7 12.4 14.3 16.3 18.8 21.4 24.7

400 400.0 401.0 6.3 7.3 9.4 10.9 14.0 16.1 18.4 21.2 24.1 27.6

450 450.0 451.0 7.1 8.2 10.6 12.2 15.7 18.1 20.7 23.9

500 500.0 501.0 7.9 9.1 11.8 13.6 17.4 20.1 22.9 26.5

550 560.0 561.0 8.8 10.2 13.2 15.2 19.5 22.5

630 630.0 631.0 10.0 11.5 14.8 17.1 21.9 25.3

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3.2 PIPES : PART II : MPVC

MPVC pressure pipes shall be manufactured in accordance with the requirements of

Jaswic specification No. R55. The factory shall be accredited in accordance with
ISO 9002. The standard effective length shall be 6 metres which shall exclude the
integral rubber ring joint.
Outside diameters listed, are constant for all classes of a given size and shall be
measured on the barrel of the pipe. There shall be six classes as shown in Table
3.2.1 (the required class will be specified by the engineer):

Table 3.2.1 Classes of MPVC pipe

Class Maximum working pressure at 25 C

kPa Head of water (m)

6 600 60
9 900 90
12 1200 120
16 1600 160
20 2000 200
25 2500 250

Nominal sizes shall be as shown in Table 3.2.2 (the required size will be specified by
the Engineer):
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Table 3.2.2 : Nominal sizes and wall thickness for MPVC pipes.

Nominal Outside Wall Thickness (mm)

Size Diameter
(mm) (mm)

Class 6 Class 9 Class 12 Class 16 Class 20 Class 25

Min Max Min Max Min Max Min Max Min Max Min Max Min Max
50 50.0 50.2 1.5 1.7 1.5 1.7 1.7 1.9 2.2 2.4 2.7 3.0 3.3 3.6
63 63.0 63.2 1.5 1.7 1.6 1.8 2.1 2.3 2.7 3.0 3.4 3.8 4.1 4.5
75 75.0 75.3 1.5 1.7 1.9 2.1 2.5 2.8 3.2 3.5 4.0 4.4 4.9 5.4
90 90.0 90.3 1.8 2.0 2.2 2.4 3.0 3.3 3.9 4.3 4.8 5.3 5.9 6.5
110 110.0 110.4 2.2 2.4 2.7 3.0 3.6 4.0 4.7 5.2 5.8 6.4 7.2 7.9
122 122.0 122.3 2.4 2.6 3.0 3.3 4.0 4.4 5.2 5.7 6.5 7.2 8.0 8.8
125 125.0 125.4 2.5 2.8 3.1 3.4 4.1 4.5 5.4 6.0 6.6 7.3 8.2 9.0
140 140.0 140.5 2.8 3.1 3.5 3.9 4.6 5.1 6.0 6.6 7.4 8.1 9.1 10.0
160 160.0 160.5 3.2 3.5 4.0 4.4 5.2 5.7 6.9 7.6 8.5 9.4 10.4 11.5
177 177.0 177.6 3.5 3.9 4.4 4.8 5.8 6.4 7.7 8.5 9.4 10.3 11.5 12.7
180 180.0 180.6 3.6 4.0 4.4 4.9 5.9 6.5 7.8 8.6 9.5 10.5 11.7 12.9
200 200.0 200.6 3.9 4.3 4.9 5.4 6.5 7.2 8.6 9.5 10.6 11.7 13.0 14.3
225 225.0 225.7 4.4 4.9 5.5 6.1 7.3 8.0 9.6 10.6 11.9 13.1 14.7 16.2
250 250.0 250.8 4.9 5.4 6.1 6.7 8.1 8.9 10.7 11.8 13.2 14.5 16.3 17.9
280 280.0 280.9 5.5 6.1 6.9 7.6 9.1 10.0 12.0 13.2 14.8 16.3 18.2 20.0
315 315.0 316.0 6.2 6.8 7.7 8.5 10.2 11.2 13.4 14.8 16.6 18.3
355 355.0 356.0 7.0 7.7 8.7 9.6 11.5 12.7 15.2 16.7 18.7 20.6
400 400.0 401.0 7.8 8.6 9.8 10.8 12.9 14.2 17.1 18.8 21.1 23.2
450 450.0 451.0 8.9 9.8 11.0 12.1 14.6 16.1 19.2 21.1 23.7 26.1
500 500.0 501.0 9.8 10.8 12.2 13.4 16.2 17.8 21.3 23.4 26.4 29.0
550 550.0 551.0 11.0 12.1 13.5 12.1 17.8 19.6 23.4 25.7
630 630.0 631.0 12.5 13.8 15.4 16.9 20.4 22.5 26.9 29.6

SECTION 4 : DESIGN CONSIDERATIONS

4.1 CLASSIFICATION : PART I : uPVC

4.1.1 Pipes of Nominal Diameter up to 630 mm

Pipes of nominal diameter up to 630 mm are classified according to the maximum

working pressure at 25 degrees C as given in Table 3.1.1.

The design engineer, who is qualified to judge the conditions of laying and
operational suitability of the pipes, must decide the class of pipe to be used, in
relation to the hydraulic design pressure (which must include surge overpressure)
and other conditions of laying and operation he has determined.

The Engineer shall also take into account the effect of all possible external loads.
DWS 1160 12
PVC Pipes

4.1.2 Couplings

The coupling shall form an integral part of the pipe and each pipe shall have one
plain end and one socket-end. At the socket-end the joint shall be integrally moulded
into the pipe. In order to retain the same hoop stress after belling the pipe wall shall
be thickened accordingly in the vicinity of the joint. The wall thickness shall conform
to the appropriate values given in Table 3.1.2 and the wall thickness of integral
pipe-end sockets shall not be less than 1,6 mm or the value obtained from the
following formula, whichever is the greater:

e (mm) = pd/(2S-p) where:

d is the average inside diameter of the main body of the
socket, in millimetres;

S is the design stress for uPVC pipes in kilopascals and shall

be 10 000 kPa;

p is the numerical value of the maximum working pressure

of the pipe of which the socket forms a part, in kilopascals.

The rubber seal ring must be designed to ensure a watertight joint under low or high
pressure operation. It must be a precision injection moulded ring, manufactured to
the requirements of SABS 974 and it must be factory fitted with a plastic retaining
ring.

4.1.3 Design Stress

A design stress of 10 MPa for Pipe sizes up to and including 90 mm and a design
stress of 12,5 MPa for pipe sizes of 110 mm and larger must be used to calculate the
wall thickness, based on a 50 year strength of at least 25 MPa, giving a minimum
safety factor of 2.5 and 2.0 respectively.

4.1.4 Resistance to Hydrostatic Pressure (ISO /DIS 4422 Part 2)

When tested in accordance with ISO 1167, using the combinations of test
temperatures and induced stresses given in Table 4.1.4; the pipe shall not fail in less
than the time specified.

Table 4.1.4 : Resistance of uPVC pipes to hydrostatic pressure

Test Temperature Induced Stress Time

degrees C MPa h

20 42 1
20 35 100
20 32 1000

60 12.5 1000
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4.2 CLASSIFICATION : PART II : MPVC

4.2.1 Pipes of Nominal Diameter up to 630 mm

Pipes of nominal diameter up to 630 mm are classified according to the maximum

working pressure at 25 degrees C as given in Table 3.2.1.
The design engineer, who is qualified to judge the conditions of laying and
operational suitability of the pipes, must decide the class of pipe to be used, in
relation to the hydraulic design pressure (which must include surge overpressure)
and other conditions of laying and operation he has determined.
The Engineer shall also take into account the effect of all possible external loads.

4.2.2 Couplings

The coupling shall form an integral part of the pipe and each pipe shall have one
plain end and one socket-end. At the socket-end the joint shall be integrally moulded
into the pipe. In order to retain the same hoop stress after belling the pipe wall shall
be thickened accordingly in the vicinity of the joint. The wall thickness shall conform
to the appropriate values given in Table 3.2.2 and the wall thickness of integral
pipe-end sockets shall not be less than 1,5 mm or the value obtained from the
following formula, whichever is the greater:
e (mm) = pd/(2S-p) where

d is the average inside diameter of the main body of the

socket, in millimeters;

S is the design stress for MPVC pipes in kilopascals and

shall be 18 000 kiloPascals;

p is the numerical value of the maximum working pressure

of the pipe of which the socket forms a part, in kilopascals.

The rubber seal ring must be designed to ensure a watertight joint under low or high
pressure operation. It must be a precision injection moulded ring, manufactured to
the requirements of SABS 974 and it must be factory fitted with a plastic retaining
ring.

4.2.3 Design Stress

A design stress of 18 MPa must be used to calculate the wall thickness, based on a
50 year strength of at least 25 MPa, giving a safety factor of 1,4.

4.2.4 Resistance to Hydrostatic Pressure (ISO /DIS 4422 Part 2)

When tested in accordance with ISO 1167, using the combinations of test
temperatures and induced stresses given in Table 4.2.4, the pipe shall not fail in less
than the time given. When a pipe is tested to faillure at 20C or 60C (at a time
longer than 1000 h) the mode of failure shall be of a ductile nature with signs of
swelling and stress whitening. (JASWIC R 55/1994, SABS 966 Part II - Draft
Specification).
DWS 1160 14
PVC Pipes

Table 4.2.4 Resistance of pipes to hydrostatic pressure

Test Temperature Induced Stress Time

degrees C MPa h

20 40 1
20 35 100
20 32 1000
60 12.5 1000

4.3 PIPE DESIGN

4.3.1 General

Buried pipelines carrying water under pressure are subjected to two main categories
of loadings:

(a) Internal pressures consisting of the known operating pressures (positive and
negative) and water hammer overpressures and is dealt with by hydraulic
design.

(b) External loadings which include the mass of the backfill above the pipe and
any vertical moving load, and is dealt with by the structural design.

4.3.2 Dimensions

The nominal internal diameter, external diameter, wall thickness of pipes and
tolerances shall be in accordance with Tables 3.1.2 and 3.2.2 of this Specification.
The effective length of the pipe, excluding the integral socket joint, shall be 6 metres
unless otherwise ordered by the Employer.

4.3.3 General Appearance and Finish

Both the inner and outer surfaces of pipes shall be smooth and free from grooving,
blistering and other deletarious defects. A plain end of a pipe shall be clean cut and
shall be externally chamfered (at an angle of approximately 15 degrees) to half the
wall thickness of the pipe. Both ends of a pipe shall be free from chips and rough
edges and shall be square to the axis of the pipe.

4.3.4 Hydraulic data

Hydraulic data shall be based upon the standard Colebrook-White formula.

Colebrook White's effective surface roughness k shall be as follows to provide for all
local head-losses:
 k = 0,025 mm for discharge mains with a relatively small
number
of fittings;
k = 0,100 mm for distribution pipelines with all types of
reticulation fittings; and economic flow velocities shall be
between 1 m/s and 3 m/s.

Flow velocities in excess of 1 metre / second can lead to the formation of

water hammer conditions and the relevant calculations should be made in
order to determine the suitability of the selected pipe pressure class.

4.3.5 Marking

The following information shall appear in legible and durable printing on each pipe at
intervals of lengths not exceeding 2 m:

(a) The manufacturer's name or trade mark

(b) material - uPVC or MPVC as applicable
(c) the class of pipe
(d) the nominal size of the pipe
(e) the batch identification

4.4 PIPELINE DESIGN

4.4.1 General

The necessary hydraulic structural and economic assessments shall be made in

accordance with recognised practice. The factors taken into account shall include
the following service conditions:

(a) Maximum and minimum internal pressures including surge and external
loads.
(b) The nature of the water conveyed.
(c) The nature of the soil and the likelihood of subsidence.
(d) The presence of water and/or contaminants in the soil around the pipe.
(e) Special attention must be given to negative pressures which may tend to
distort the pipeline.
(f) Any other conditions which might affect the pipeline,

4.4.2 Access to the Pipeline

The design shall take full account of the pipeline route and layout to ensure that
adequate access is available to all parts of the pipeline for future inspection and or
maintenance work.
4.4.3 Structural Design

4.4.3.1 General

The structural strength of the pipeline shall be made adequate to withstand the worst
combination of external load and internal pressure.

4.4.3.2 External loading

All PVC pipes shall be considered as flexible. Pipe joints are flexible and do not
transfer any load.

To determine the class of pipe and type of bedding necessary to resist external loads
from backfill, traffic, etc. the calculations shall be based on geotechnical principles
used in pipeline design.

4.4.3.3 Internal pressure

The internal pressure shall consist of the known operating pressure plus the
overpressure due to the effect of water hammer.

4.3.4.4 Angular deviation at joints

The flexible joint shall be able to accommodate a deflection angle of 0,5 degrees for
all pipe sizes.

4.4.3.5 Allowable longitudinal bending

For pipes 400 diameter and smaller, controlled longitudinal bending will be allowed
provided the bending radius is not smaller than 300 D where D is the outside
diameter of the pipe in metre. Table 4.4.3.5 indicates the allowable longitudinal
bending of a 6 m PVC pressure pipe, excluding allowance for joint deflection.
 Table 4.4.3.5 : Allowable longitudinal bending of a 6 m pipe, excluding
allowance for joint deflection
Size (mm) Offset (mm)
50 1190
63 945
75 795
90 660
110 540
125 475
140 425
160 375
200 295
250 240
315 185
355 165
400 150

4.4.3.6 Pipelines on steep gradients

Pipelines laid on gradients of 1 in 6 or steeper shall be anchored into solid ground at

the spacing given in Table 4.4.3.6 to prevent movement.
Table 4.4.3.6 : Spacing of anchors on steep slopes
Gradient Spacing
1 in 2 or steeper 6m
Below 1 in 2 to 1 in 4 12m
Below 1 in 4 to 1 in 5 18m
Below 1 in 5 to 1 in 6 24m
Flatter than 1 in 6 not required

4.4.3.7 Anchors and thrust blocks

Anchors and thrust blocks shall be designed to withstand the forces resulting from
the internal pressure when the pipeline is under test. The internal pressure acts over
the full external cross section of the pipe at each joint, and the direction of the
resultant thrust may change on the occurrence of any negative pressure due to
surge.
Where pipes pass through solid structures, it is essential to provide flexibility to the
pipeline at either side of the structure. This shall be effected by introducing two
flexible joints to the pipeline on each side of the structure, that the first joint is no
more than one pipe diameter or 600 mm, whichever is greater, from the structure
and the second is approximately 1,5 diameter from the first. At the point of pipe
entry into the structure the pipe's circumference shall be wrapped with a 10 to 20 mm
thick (depending on the pipe diameter) and 200 mm wide band of a non-degradable
compressible material (rubber) to help the pipe to absorb the stresses resulting from
pipe deflection outside the structure. In addition, at this point it is necessary to
increase the bed depth to not less than one pipe diameter for a length not less than
two pipe diameters and trench width to minimum of three pipe diameters for a length
of three to five pipes diameters.

Where water tightness between pipe and structure is required, the advice of the pipe
manufacturer shall be sought.

Anchors and thrust blocks shall be designed to withstand 1,5 times the maximum
allowable sustained pressure.

4.4.3.8 Pipelines on intermittent supports

 PVC pipelines shall not be laid where it is exposed to sunlight and ultraviolet light
radiation, or where it can be damaged by the general public.

For pipelines laid in tunnels, or culverts, on cradles, or on piles (poor ground), special
precaution in design and construction shall be made.

No fewer than three supports shall be provided for each pipe, situated in the center
of the pipe and one metre from each end. Supports shall be shaped to give 120
degrees angle of support. To ensure that the pipe circumference is uniformly
supported, a layer of durable flexible material at least 6 mm thick (such as bitumen
impregnated felt) must be inserted between the pipe and support contact surfaces.
The width of the support shall be not less than 150 mm.

If the pipeline is laid in a tunnel or culvert which is liable to flood, PVC pipes shall not
be used.

4.5 CORROSION PROTECTION

4.5.1 Pipes and Fittings

Due to its inorganic nature, unplasticised polyvinyl chloride is resistant to fungus,

bacterial decay and biological attacks. Electrolysis have no influence on the stability
of PVC and no corrosion can occur under the influence of oxygen and humidity.

4.5.2 Fittings of SG Iron

All fittings manufactured from spheroidal graphite iron shall be bitumen dipped for
protection against corrosion.

4.5.3 Bolted Joints

This clause is only applicable on larger pipes where metallic flanged adapters or
similar fittings are used. Joints shall be protected as per Clause 9.8 in Specification
DWS 1110. Briefly, protection shall be afforded by packing a suitable mastic material
over the components and the adjacent external surface of the pipe so as to form a
continuous layer with a smooth profile which shall subsequently be wrapped with a
compatible cold applied tape. Care shall be taken to ensure that there are no voids
between the mastic and pipe component, nor between the tape and the mastic.

SECTION 5 : CONSTRUCTION

5.1 TRANSPORT, PACKAGING, HANDLING AND STORAGE

5.1.1 Transport

Whatever the length of journey, and whether at the works or on site, pipes shall be
loaded for transport in such a way that they are secure and that no more than an
absolute minimum of movement can take place on the vehicle during transit. Sharp
projections or edges shall be padded to limit the chafing action that occurs between
the vehicle body and pipe whilst the vehicle is in motion. A flat -bodied vehicle is
ideal for transporting PVC pipes.

5.1.2 Packaging

Normal steel strapping over cardboard padding is ideal packaging material. Care
shall be taken to ensure that the strapping is not overtightened.
5.1.3 Handling and Storage

5.1.3.1 General

Due to the extreme lightness of PVC pressure pipes, there is a tendency for the pipe
to be thrown off vehicles onto the ground during off-loading. This shall not be
allowed as damage can occur to the ends of the pipe. Pipes shall be stacked with
the socket and spigot ends alternating and with sockets projecting so that there is
barrel to barrel contact along the lengths of the pipe. Pipes may not be stacked
higher than 1,0 m above natural ground level. Heavy pipes shall be placed at the
bottom of the stack. Pipes shall be stored in the shade to eliminate distortion caused
by excessive heat. Long term exposure to sunlight and ultra-violet light radiation
shall be avoided. Storage for longer than six months shall be under cover.

When pipes are temporarily stored in the field, care shall be taken to ensure that the
ground is level and free from loose stones.

It is of the utmost importance that the area around the pipes is free from dry grass or
any material likely to constitute a fire hazard.

5.1.3.2 Off-loading

Off-loading of smaller pipes can be done by hand. Larger pipes must be rolled down
skid-timbers under restraint of ropes passed around both ends of the pipe. When
cranes are used, rope or nylon slings or lifting beams with padded flattened hooks
shall be used. It is essential that steadying ropes are used.
5.1.3.3 Stacking

The first layer of pipes shall be placed on a firm foundation consisting of solid
timbers set level on the ground. Wedges shall be firmly nailed to the timbers to
prevent the pipes from moving. The following layers shall have one less pipe than
the layer below, forming a tapered stack. The height of any stack shall not exceed
1,0 m.

5.1.3.4 Stringing

Stringing consists of placing pipes on the ground in line ready for laying. Care shall
be taken to prevent damage during this operation.

5.2 TRENCHING, LAYING AND BACKFILLING

5.2.1 Trenching

Trenching includes any excavation which is carried out by trenching machine,

excavator, or hand, to prepare the trench to the required dimensions for the pipeline.
The excavation shall be properly supported, or the sides sloped back to a safe angle,
before the excavation reaches a depth of 1,2 m. The stability of the excavation shall
be assured in relation to the safety of services, structural conditions and likely
movement.

The trench shall not be wider than 400 mm plus the diameter of the pipe. The depth
of bedding below the pipe shall not be less than 100 mm. The total cover on top of
the pipe shall not be less than 900 mm unless agreed to by the Engineer and the
manufacturer.

The length of open trench in advance of the pipe laying operation shall not exceed
200m. It is of the utmost importance that pipes must be backfilled immediately after
laying, with only the joints left open for testing.

5.2.2 Trench Preparation

The preparation of the trench bed to provide an even bed for the pipe and the proper
alignment of the pipes, is of primary importance. Holes shall be provided with
sufficient room for the joint to be properly made and to ensure that the pipe rests on
the barrel and not on the joint.

The trench bed must be free from all stone or hard projections which are likely to
cause damage to the pipe.

Where groundwater conditions are such that there is a risk of the trench backfill
being washed away, suitable impermeable stops (e.g. clay cut-off walls) shall be
provided at appropriate intervals to prevent longitudinal drainage.
DWS 1160 21
PVC Pipes
Where groundwater is present, a drainage zone shall be constructed in the bottom of
the excavated trench. The drainage zone of granular material, of single size
compacted 20 mm aggregate shall be encased in geotextile fabric to prevent the
fines from the adjacent bedding, trench bed and walls to migrate into the granular
material.

5.2.3 Bedding

All leveling and side sheeting must be removed before placing bedding. The bottom
of the trench shall be backfilled to a depth of 100mm with suitable bedding material
such as free draining coarse sand, gravel, or soil of a friable nature. The size of
98.75% by weight of particles in the bedding material shall not exceed 20mm. All
bedding material shall conform to SABS 1200 Section LB. The suitability of soil for
use as bedding material shall be determined as follows:

(a) Cut a length of 250 mm from a pipe 160mm in diameter and stand the cut
length upright on a level surface.

(b) Take a representative sample of the bedding material with moisture content
similar to that of the main source and then loosely fill the pipe with this
material.

(c) Empty the bedding material from the pipe into a suitable container.

(d) Using the same bedding material from the container, refill the pipe in 60 mm
layers, firmly tamping each layer with a metal hammer weighing 1 kg and
having a striking face of approximately 40 mm diameter.

(e) Use all material from the container tamping continually until no further
compression of the material occurs. Measure the distance from the top of
the pipe to the surface of the tamped material. If this measurement
does not exceed 25 mm, the material is suitable for use as bedding
material.

The bedding shall be carefully and thoroughly compacted to produce a level uniform
bed onto which the pipe is directly laid.

5.2.4 Inspection of Pipe before Laying

All spigots must be checked to ensure that they are free from burrs. Both the spigot
and socket surfaces must be carefully cleaned with a dry cloth. It is important to
ensure that the rubber ring is clean and free of stones and grit. The spigot end must
have a uniform chamfer of approximately 15 degrees around the external
circumference of the pipe to approximately half the wall thickness. The depth of
entry must be marked on the spigot by the manufacturer and must be so positioned
so as to be just visible outside the mouth of the socket. It is of the utmost
importance that there are no scratches, marks, indentations or similar damage
visible on both the inside and outside of the pipe. If such damage are observed the
pipe shall be discarded and removed from the site.
DWS 1160 22
PVC Pipes
5.2.5 Laying and Jointing

5.2.5.1 Laying

Pipes shall be lowered into the trench with tackle suitable for the mass of pipes
lengths. All persons shall vacate any section of trench into which a pipe is being
lowered. All debris shall be cleared from the inside of the pipe before a joint is
made. When laying is not in progress the open end of the pipeline shall be fitted with
a temporary end closure.

5.2.5.2 Jointing

Jointing procedure will vary according to the type of joint being used. Basic
requirements for all types are:
(a) Cleanliness of all parts
(b) Correct assembly of components
(c) Proper alignment of pipes
(d) Proper location of joint sleeve (where applicable)
(e) Proper lubrication
(f) Strict compliance with manufacturer's jointing instructions.

5.2.5.3 Anchoring

Pipelines must be anchored at all changes of directions, at all valves, all stop ends
and reducers. Concrete anchor blocks shall be used at all anchor points. Where
anchor blocks are in direct contact with the pipe (at bends), the bend shall be
protected by means of a layer of plastic sheeting. It is important that all anchor
blocks shall be extended onto the socket area of the fitting that is being anchored,
and shall be keyed into the sides and bottom of the trench.

5.2.5.4 Flanges and flexible couplings

When piping is to be encased in concrete and when thurst blocks are casted,
concrete faces shall be minimum of 225mm from flanges and 300mm from flexible
coupling centres.

5.2.6 Backfilling

Backfilling over PVC pipes shall be in accordance with drawing LB 2 (a), LB 3 (d)
and LB 5 (b) of SABS 1200 LB. This is extremely important and the Engineer shall
use special supervision to ensure this.

It is essential that PVC pressure pipes are backfilled immediately after each pipe is
installed, in order to contain the expansion and contraction that may occur in an open
trench. Immediate backfilling restricts expansion and contraction to each individual
pipe length where it is catered for by the integral rubber joint.

Backfilling of piping shall be carried out in two phases:

 Phase 1 involves partial backfilling before pressure testing;

 Phase 2 involves completion of backfilling after pressure testing.

5.2.6.1 Side-filling and initial backfilling

DWS 1160 23
PVC Pipes

Before side-filling can commence the contractor shall check that the depth of entry
mark is just visible on all joints. Granular material as described in Clause 5.2.3 (a) to
(e) shall be placed gently and evenly in uncompacted layers of 75 mm maximum
between the sides of the trench and the pipe. Each layer shall be firmly tamped with
a hand tamper until reaching 100 mm above the crown of the pipe, taking care to
ensure that no voids are left under the pipe. It is important that all joints must be left
exposed at this stage. Movement of the pipe shall be prevented by the simultaneous
filling and even compaction of bedding material on either side of the pipe.

Selected fill material shall be placed in even and uncompacted layers of not more
than 150 mm in thickness over the entire width of the trench to a height of 300 mm
above the crown of the pipe. All layers must be firmly tamped by hand tampers. All
joints shall still be exposed at this stage.

5.2.6.2 Comman Backfill

The remainder of the trench, excluding the areas where joints must still remain
exposed, shall be backfilled in uncompacted layers of 300 mm maximum. Each
layer must be firmly tamped - the first layer by hand tamper and subsequent layers
by mechanical means.

The Engineer must approve the material used for backfilling. The backfill material
must comply with Clause 3.16 of Specification DWS 1110: Construction of pipelines.

Where selected excavated material from the trench is used for backfilling it shall be
free from debris, organic material or large stones. Care shall be taken to ensure that
pipes are not damaged by compaction equipment during backfilling. In an
agricultural land the topsoil shall be left in a loose workable condition to its original
full depth over the full trench width and shall be as free from stones as the adjacent
land.

After the successful pressure testing of the pipe, joints shall be backfilled in the
same manner as specified above. Special care shall be exercised to remove all
debris, large stones and undesirable matter from these joint holes before backfilling
commences.

Backfilling of trenches shall be compacted to 90% modified AASTHO density.

Where mechanical equipment is employed on the site, care shall be taken to avoid
damage to the pipeline.

5.3 CLEANING, TESTING AND STERILISATION

5.3.1 Cleaning

Before a pipeline can be considered ready for service it shall be thoroughly cleaned
internally to ensure that no foreign matter remains inside the pipe.

5.3.2 Hydrostatic Testing

The maximum length of pipe to be tested shall not exceed 1000m. The test section
shall be isolated to limit water loss in the event of a failure. The test section shall be
plugged with end-caps or end-plugs fitted with inlets and outlets for filling and
bleeding purposes. The plugged ends must be braced to prevent movement when
pressure is applied to the pipeline.

Before filling the line the contractor shall check
blocks are set and that if the pipeline goes over
prevent the pipes from lifting due to thrust. All air
isolating valves must be opened to release the air
be closed.
that all joints are exposed, thrust
a rise, there is enough backfill to
valves must be removed and their
when filling. All scour valves shall
DWS 1160 24
PVC Pipes

The test section shall be filled from the lowest point. The filling rate must be in
accordance with Table 5.3.2.1.

Table 5.3.2.1 : Filling rate for PVC pipes

Size (mm) litres/minute
50 5
63 8
75 11
90 15
110 20
125 30
140 37
160 50
200 95
250 150
315 215
355 290
400 380
450 477
500 589
550 712
630 935

The pipeline shall be allowed to adequately bleed through the isolating valves to
ensure that all the air has been removed from the system before closing the isolating
and other bleed valves. After filling the pipeline it must be allowed to stand for 12
hours under static pressure to allow any remaining air to reach the highest point. No
pressure shall be applied during this 12 hour period. Hereafter the line shall be
inspected for leaks and settlement. Top up the line after 12 hours and bleed again to
get rid of any remaining air. The presence of air can seriously affect the results of
pressure test operations.

The pressure shall be applied slowly by means of a suitable test pump. While the
pressure is being raised, care shall be taken to release further quantities of air. The
hydraulic test pressure shall not exceed 1.25 times the stated pressure of the class of
pipe under test. Pressure readings shall be taken from the lowest point of the test
section. Once the pipeline has been pressurised to the test pressure, the drop in
pressure must be recorded every 15 minutes whereafter the test pressure must be
restored and the make-up water recorded. This procedure shall be carried out for 60
minutes. The leakage rate in litres per kilometre per hour shall not exceed the
values given in Table 5.3.2.2, PART I : uPVC or Table 5.3.2.3, PART II, MPVC.
DWS 1160 25
PVC Pipes
Table 5.3.2.2 : PART I : uPVC
Allowable Leakage Rates (ALR) in Litres/Kilometre/Hour ( Based on test
pressure = 1.5 x rated pressure of the pipe)

Pipe Outside Test Pressure Test Pressure Test Pressure Test Pressure
Diameter 900 kPa 1350 kPa 1800 kPa 2400 kPa
(mm) (Class 6) (Class 9) (Class 12) (Class 16)

ALR ALR ALR ALR

50 0.7 1.1 1.5 2.0
63 0.9 1.4 1.9 2.5
75 1.1 1.7 2.3 3.0
90 1.3 2.0 2.7 3.6
110 1.6 2.4 3.3 4.4
125 1.8 2.8 3.7 5.0
140 2.0 3.2 4.2 5.6
160 2.3 3.6 4.8 6.4
200 2.8 4.5 5.0 8.0
250 3.6 5.6 7.5
315 4.5 7.1
355 5.0 8.0
400 5.7 9.0
450 6.8 10.1
500 7.5 11.2
550 8.3 12.4
630 9.5 14.2

For pipelines shorter than 30 m in length, the maximum pressure loss after 1 hour
test period shall not exceed 50 kPa.
DWS 1160 26
PVC Pipes
Table 5.3.2.3 : PART II : MPVC
Allowable Leakage Rates (ALR) in Litres/Kilometre/Hour (Based on test
pressure = 1.25 x rated pressure of the pipe)
Pipe Test Test Test Test Test Test
Outside Pressure Pressure Pressure Pressure Pressure Pressure
Diameter 750 kPa 1125 kPa 1500 kPa 2000 kPa 2500 kPa 3125 kPa
(mm) (Class 6) (Class 9) (Class 12) (Class 16) (Class 20) (Class 25)
ALR ALR ALR ALR ALR ALR ALR
50 0.43 0.53 0.61 0.71 0.79 0.88
63 0.55 0.67 0.77 0.89 1.00 1.11
75 0.65 0.80 0.92 1.06 1.19 1.33
90 0.78 0.95 1.10 1.27 1.42 1.59
110 0.95 1.17 1.35 1.57 1.74 1.94
125 1.08 1.33 1.53 1.77 1.98 2.21
140 1.12 1.48 1.71 1.98 2.21 2.47
160 1.39 1.70 1.96 2.26 2.53 2.83
200 1.73 2.12 2.45 2.83 3.16 3.54
250 2.17 2.65 3.06 3.54 3.95 4.42
315 2.73 3.34 3.86 4.46 4.98 5.57
355 3.07 3.77 4.35 5.02 5.61 6.28
400 3.46 4.24 4.90 5.66 6.32 7.07
450 3.90 4.77 5.51 6.36 7.12 7.95
500 4.33 5.30 6.12 7.07 7.91 8.84
550 4.76 5.85 6.73 7.78 8.70 9.72
630 5.46 6.68 7.72 8.91 9.96 11.14

For pipelines shorter than 30 m in length, the maximum pressure loss after 1 hour
test period shall not exceed 50 kPa.

5.3.3 Sterilisation

Pipelines intended to convey potable water shall be sterilised in accordance with

DWS 1110: Clause 13.

The pipeline shall not be put into service until the water at each sampling point,
having stood in the pipeline for 24 hours, has maintained a satisfactory potable
standard.
After sterilization, the chlorinated water shall receive treatment to dilute the chlorine
to an acceptable level before discharging to waste.

5.4 MEASUREMENT AND PAYMENT

The measurement and payment shall be in accordance with DWS 1110: Clause 20
where applicable.